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CHAPTER - 6
Reverse Engineering
REVERSE ENGINEERING
•encompasses any activity that is done to determine how a product works, to learn the ideas and technology that were used in developing that product.
REVERSE ENGINEERING ?
Process of analyzing a product’s function
Begins with a product
Ends with understandin
g
REVERSE ENGINEERING
Important step in the
Design Process
REVERSE ENGINEERING• Decreases Product Waste• Develop replacement parts for old equipment• Create detailed documentation to manufacture old products for which documentation is not available
Precision measurements are taken CAD programs used to generate solid models
Reverse Engineering and Patents•Patent lawDesigned to protect inventors•Competitor may reverse engineer and copy a design•Recourse: sue for patent infringement
Reverse Engineering
Reverse Engineering
Series of Logical Steps
Not necessarily followed in linear fashion
Move back and forth between the steps
Reverse Engineering- BIG PICTURE
1.Identify the
Purpose
2.Develop a
hypothesis
3.Disassemble
4.Analyze the
Elements
5.Prepare the
Report
6.Redesign
PROCESSFLOW-CHART
Reverse Engineering- BIG PICTURE
1.Identify the
Purpose
2.Develop a
hypothesis
3.Disassemble
4.Analyze the
Elements
5.Prepare the
Report
6.Redesign
PROCESSFLOW-CHART
Reasons for REVERSE ENGINEERING
Research similar products to discover ideas for more competitive products
Test a product to determine cause of failure
Continuous product improvement
Create documentation for components lacking original documentation
Reasons for REVERSE ENGINEERING
Learn about structure, function, manufacturing, and aesthetics
Design replacement parts for products no longer in production
Develop CAD and CNC data to enhance manufacturing processes
REVERSE ENGINEERING STEP BY STEP
1.Identify the Purpose
2.Develop a hypothesis
3.Disassemble
4.Analyze the
Elements
5.Prepare the Report
6.Redesign
1. Identify the Purpose
•Determine what needs to be learned•Record purpose in engineer’s notebook
2. Develop a Hypothesis•HypothesisStatement that suggests a possible, unproven answer to a question
•Describe hypothesis of product function•Write down questions and possible answers
3. Disassembly•Disassembly process called teardown•Carefully disassemble to uncover internal components and mechanisms•Must be done in organized fashionKeep careful notesOrganize parts with labels and plastic bagsTake photos during the process
4. Analyze the Elements•Attempt to answer the questions originally posed•Four types of analysisFunctionalStructuralMaterialsManufacturing
5. Functional Analysis•Discover how the product works•Take measurements or perform tests on componentsTools: micrometers and calipers
6. Structural Analysis•Determine purpose of each part•Determine how parts interact with each other•Finite Element AnalysisUsed to learn more about structural qualities
7. Materials Analysis• Identify material by its common name•Useful to know what the manufacturing process is•Material properties may be determined by testing•Molded plastic parts may be labeled with the material type or symbol
8. Manufacturing Analysis
•Types of manufacturing processesFormingSeparationJoining
9. Prepare the Report
•Communicate findings in a clear and concise manner•Confirm purpose of the reverse engineering has been addressed
10. Product Redesign
•Make recommendations for design change based on findings•May lead to development of accessoriesExample: cell phone covers